Medical drape with pattern adhesive layers and method of manufacturing same

Abstract

A medical drape for use with a reduced pressure system for providing reduced pressure to a tissue site is described. In some embodiments, the drape may include a flexible film, and an adhesive layer coupled to the flexible film. The adhesive layer may include a first adhesive disposed on a first portion of the flexible film in a first pattern. The first adhesive can be configured to secure the flexible film proximate to the tissue site. The adhesive layer generally includes a second adhesive disposed on a second portion of the flexible film in a second pattern. The second adhesive can be configured to seal the flexible film proximate to the tissue site. The first pattern and the second pattern are preferably registered so that the first portion and the second portion are offset to cover substantially different portions of the flexible film.

We claim: 
     
       1. A method of manufacturing a medical drape, the method comprising:
 providing a flexible film; having a planar surface 
 disposing a first adhesive on the planar surface in a first pattern; and 
 disposing a second adhesive on the side of the flexible film in a second pattern, so that the first adhesive and the second adhesive cover different portions of the planar surface; the second adhesive having a thickness less than a thickness of the first adhesive. 
 
     
     
       2. The method of  claim 1 , wherein disposing the first adhesive and the second adhesive comprises covering the planar surface with the first adhesive and the second adhesive. 
     
     
       3. The method of  claim 1 , wherein disposing the first adhesive and the second adhesive comprises collectively covering a portion of the side of the flexible film. 
     
     
       4. The method of  claim 1 , wherein disposing the first adhesive on the planar surface in the first pattern comprises:
 moving the flexible film past a rotary member so that the flexible film contacts a portion of an exterior of the rotary member while the flexible film moves linearly relative to the rotary member; 
 supplying the first adhesive to an interior of the rotary member; and 
 compressing the first adhesive through openings of the rotary member onto the flexible film, the openings being formed in the exterior surface of the rotary member in the first pattern. 
 
     
     
       5. The method of  claim 1 , wherein disposing the second adhesive on the planar surface in the second pattern comprises:
 moving the flexible film past a rotary member so that the flexible film contacts a portion of an exterior of the rotary member while the flexible film moves linearly relative to the rotary member; 
 supplying the second adhesive to an interior of the rotary member; and 
 compressing the second adhesive through openings of the rotary member onto the flexible film, the openings beings formed in the exterior surface of the rotary member in the second pattern. 
 
     
     
       6. The method of  claim 1 , wherein disposing the first adhesive on the planar surface in the first pattern comprises:
 providing one or more extruders configured to receive the first adhesive and operable to extrude the first adhesive onto the flexible film; 
 moving the flexible film relative to the extruders; and 
 actuating the extruders to extrude the first adhesive onto the flexible film as the flexible film moves linearly past the extruders. 
 
     
     
       7. The method of  claim 1 , wherein disposing the second adhesive on the planar surface in the second pattern comprises:
 providing one or more extruders configured to receive the second adhesive and to extrude the second adhesive onto the flexible film; 
 moving the flexible film in a first direction relative to the extruders; 
 moving the extruders linearly in a second direction perpendicular to the movement of the flexible film, the movement being cyclical between a first edge of the flexible film and a second edge of the flexible film; and 
 actuating the extruders to extrude the second adhesive through the extruders onto the first side of the flexible film as the flexible film moves past the extruders. 
 
     
     
       8. The method of  claim 1 , wherein disposing the first adhesive on the planar surface in the first pattern comprises:
 providing an extruder configured to receive the first adhesive and to extrude the first adhesive onto the flexible film; 
 moving the flexible film linearly relative to the extruder; 
 actuating the extruder to extrude the first adhesive through the extruder onto the flexible film as the flexible film moves linearly past the extruder; 
 moving the extruder linearly perpendicular to the movement of the flexible film, the movement being cyclical between a first edge of the flexible film and a second edge of the flexible film; and 
 moving the flexible film perpendicular to the extruder, the first pattern being a periodic wave-shaped strip in response. 
 
     
     
       9. The method of  claim 1 , wherein the disposing the first adhesive on the planar surface in the first pattern comprises:
 providing a transfer cylinder having the first pattern engraved on an exterior portion of the transfer cylinder; 
 coating the transfer cylinder with the first adhesive; 
 pressing the transfer cylinder onto the flexible film as the flexible film moves linearly past the transfer cylinder to deposit the first adhesive on the flexible film; and 
 curing the first adhesive on the flexible film. 
 
     
     
       10. The method of  claim 1 , wherein disposing the second adhesive on the planar surface in the second pattern comprises:
 providing a transfer cylinder having the second pattern engraved on an exterior portion of the transfer cylinder; 
 coating the transfer cylinder with the second adhesive; 
 pressing the transfer cylinder onto the flexible film as the flexible film moves linearly past the transfer cylinder to deposit the second adhesive on the flexible film; and 
 curing the second adhesive on the flexible film.